Modular extruded aluminum deck assembly

ABSTRACT

An extruded aluminum deck assembly having interlocking decking plates. The decking plates of the interlocking deck assembly have horizontally opposed, interlocking outrigging flanges. The extruded decking components comprise feet depending from a planar top surface.

BACKGROUND OF THE INVENTION Field of the Invention

This invention relates to flooring products and in particular tointerlocking planks or plates assemblable to form a deck, stage orfloor.

Description of the Related Art

Flooring assemblies temporarily constructed for a particularizedpurpose, including decks and stages. Installation of permanent deckingcan be labor intensive, sometimes requiring footings to be dug or otherconstruction. Traditional decks and flooring are fixed in place andcannot be relocated but through destructive means. Although modulardecking kits having attachable members are known in the art, they areoften fabricated from wooden or polymeric members which may warp,splinter, or rot. Most modular flooring comprises subgrade, joists,beams or framing to form a larger deck. These members are not easilysecured, transported and detached. Maintenance may be required toprotect wooden decking from the elements and seal the surface frommoisture. Variations in temperature and humidity cause them to expandand contract, which loosens the metal connection hardware. Lumber usedin constructing traditional decking is also susceptible to deteriorationby mildew, mold, and infestation.

In many instances, modular decking is not efficient or easily assembledin the construction of a decking. Modular decking components do noteffectively interlock, break easily, and are too heavy and cumbersome tobe efficiently portable. What is needed in the art is a multipurpose,lightweight decking, which does not warp with heat and moisture, whichis light, and which can be easily assembled to withstand inclementweather, harsh environments, heavy foot traffic, and is resilient whenexposed to harsh cleaning chemicals.

SUMMARY OF THE INVENTION

From the foregoing discussion, it should be apparent that a need existsfor a modular extruded aluminum deck assembly. Beneficially, such anapparatus would overcome many of the difficulties and concerns expressedabove, by providing a lightweight, easily assemblable and disassemblableproduct.

The present invention has been developed in response to the problems andneeds in the art that have not yet been fully solved by currentlyavailable apparati and methods. Accordingly, the present invention hasbeen developed to provide a modular extruded aluminum deck assembly, thedeck assembly comprising: a plurality of square panels having a planartop surface, each panel comprising: a laterally-protruding maleinterlocking member, wherein the male interlocking member comprises aconcave outrigging flange; a female receptacle for receiving the maleinterlocking member, the female receptacle defining a hollow interiorrecess with a partially open top end, the female receptacle comprising aconcave cantilevered flange for mating with the concave outriggingflange of an adjacent square panel; a foot depending beneath the planartop surface for engaging a ground surface; and a textured top surface.

The male interlocking member may comprise a cantilevered lip extendinglaterally partially across the concave outrigging flange for abutting atop edge of a male interlocking member.

The female receptacle may comprise a lower ground-engaging member havinga planar bottom surface and an inclined bottom surface angling upwards,the ground-engaging member and concave outrigging flange defining thehollow interior recess.

These features and advantages of the present invention will become morefully apparent from the following description and appended claims, ormay be learned by the practice of the invention as set forth hereinafter

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the advantages of the invention will be readilyunderstood, a more particular description of the invention brieflydescribed above will be rendered by reference to specific embodimentsthat are illustrated in the appended drawings. Understanding that thesedrawings depict only typical embodiments of the invention and are nottherefore to be considered to be limiting of its scope, the inventionwill be described and explained with additional specificity and detailthrough the use of the accompanying drawings.

FIG. 1 is a side perspective view of an extruded modular aluminumdecking plate in accordance with the present invention;

FIG. 2A is a side perspective view of a detached male outrigging flangeand a female receptacle of an extruded modular aluminum decking plate inaccordance with the present invention;

FIG. 2B is a side perspective view of a mated male outrigging flange anda female receptacle of an extruded modular aluminum decking plate inaccordance with the present invention;

FIG. 3 is a side perspective view of the foot of an extruded modularaluminum decking plate in accordance with the present invention;

FIG. 4 is a side perspective view of the female receptacle of anextruded modular aluminum decking plate in accordance with the presentinvention;

FIG. 5 is a side perspective view of the male outrigging flange of anextruded modular aluminum decking plate in accordance with the presentinvention;

FIG. 6 is a side perspective view of an alternate female receptacle ofan extruded modular aluminum decking plate in accordance with thepresent invention; and

FIG. 7 is a side perspective view of an alternate extruded modularaluminum decking plate in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Reference throughout this specification to “one embodiment,” “anembodiment,” or similar language means that a particular feature,structure, or characteristic described in connection with the embodimentis included in at least one embodiment of the present invention. Thus,appearances of the phrases “in one embodiment,” “in an embodiment,” andsimilar language throughout this specification may, but do notnecessarily, all refer to the same embodiment.

Furthermore, the described features, structures, or characteristics ofthe invention may be combined in any suitable manner in one or moreembodiments. In the following description, numerous specific details areprovided to provide a thorough understanding of embodiments of theinvention. One skilled in the relevant art will recognize, however, thatthe invention may be practiced without one or more of the specificdetails, or with other methods, components, materials, and so forth. Inother instances, well-known structures, materials, or operations are notshown or described in detail to avoid obscuring aspects of theinvention.

FIG. 1 is a side perspective view of an extruded modular aluminumdecking plate 100 in accordance with the present invention. The deckingplate 100 comprises a female receptacle 106, a planar top surface 102having texture 110, a foot 104, and a concave male outrigging flange108.

FIG. 2A is a side perspective view of a detached male outrigging flangeand a female receptacle of an extruded modular aluminum decking plate inaccordance with the present invention.

The male outrigging flange 108 comprises a cantilever 208 juttinglaterally from the planar top surface 102 partially across the concavemember 206. The concave member 206 comprises a top edge 210 which abutsthe underside of a concave cantilevered flange 202 on an adjacentdecking plate 100.

The female receptacle 106 comprises a concave cantilevered flange 202having a top edge 212 for abutting the underside of the cantilever 208of an adjacent decking plate 100, the female receptacle 106 horizontallyopposed to the male outrigging flange 108. The female receptacle 106defines a hollow interior recess 204 for receiving the male outriggingflange 108. The female receptacle 106 comprises a lower, ground-engagingmember 214 having an inclined surface. The female receptacle 106 alsocomprises a foot 216.

The underside of the concave cantilevered flange 202 substantiallycontours the topside of the male outrigging flange 108 enabling andfacilitated mating therebetween. The male outrigging flange 108 andfemale receptacle 106 interlock together at the plate 100 periphery.

FIG. 2B is a side perspective view of a mated male outrigging flange anda female receptacle of an extruded modular aluminum decking plate inaccordance with the present invention.

As shown, the male outrigging flange 108 mates with the femalereceptacle 106.

FIG. 3 is a side perspective view of the foot 300 of an extruded modularaluminum decking plate in accordance with the present invention.

The foot 300 comprises a downwardly protruding rib having two laterallyprotruding flanges 304 a-b. The laterally protruding flanges 304 a-bdistribute weight on the top surface 102 more evening on a groundsurface beneath the top surface 102.

FIG. 4 is a side perspective view of the female receptacle 400 of anextruded modular aluminum decking plate in accordance with the presentinvention. FIG. 4 as shown.

FIG. 5 is a side perspective view of the male outrigging flange of anextruded modular aluminum decking plate in accordance with the presentinvention.

FIG. 5 as shown.

FIG. 6 is a side perspective view of an alternate female receptacle ofan extruded modular aluminum decking plate in accordance with thepresent invention.

In this alternative embodiment, the concave cantilevered flange 202 indisposed beneath the top surface 102.

FIG. 7 is a side perspective view of an alternate extruded modularaluminum decking plate 700 in accordance with the present invention. Thedecking plate 700 comprises upwardly rising protrusions for improvingtraction on the top surface of the decking plate 100.

As referenced in FIGS. 1-7, a modular decking assembly comprises atleast one plate 100 that assembles to form a deck. The plates 100 matewith one another to uniformly bear the dead and/or live load weight fromindividuals or item on the top surfaces 102 of the plates 100, eachplate 100 restricting lateral movement with adjacent plates.

The plates 100 are configured to interlock with additional plates 100 toform the decking, staging or flooring. In some embodiments, the deckingmay include a floor decking, a wall, a patio, or a boat deck. The plates100 may have a generally flat, square shape.

During installation of a deck assembly, the area where the installationwill take place is preferably level. Where minor discrepancies occur,the plates 100 rotate and/or flex slightly as needed.

Additional fastening components, such as screws or bolts, may passthrough the adjacent plates and anchors may be placed on the ground tofurther stabilize the decking assembly. The assembly may be disassembledthrough by lifting and pulling apart the plates 100.

The attached drawing and description provide a modular extruded aluminumassembly. The present invention may be embodied in other specific formswithout departing from its spirit or essential characteristics. Thedescribed embodiments are to be considered in all respects only asillustrative and not restrictive. The scope of the invention is,therefore, indicated by the appended claims rather than by the foregoingdescription. All changes which come within the meaning and range ofequivalency of the claims are to be embraced within their scope.

What is claimed:
 1. A modular extruded aluminum deck assembly, the deckassembly comprising: a plurality of square panels having a planar topsurface, each panel comprising: a laterally-protruding male interlockingmember, wherein the male interlocking member comprises a concaveoutrigging flange; a female receptacle for receiving the maleinterlocking member, the female receptacle defining a hollow interiorrecess with a partially open top end, the female receptacle comprising aconcave cantilevered flange for mating with the concave outriggingflange of an adjacent square panel; a foot depending beneath the planartop surface for engaging a ground surface; and a textured top surface;2. The deck assembly of claim 1, wherein the male interlocking membercomprises a cantilevered lip extending laterally partially across theconcave outrigging flange o for abutting a top edge of a maleinterlocking member.
 3. The deck assembly of claim 1, wherein the femalereceptacle comprises a lower ground-engaging member having a planarbottom surface and an inclined bottom surface angling upwards, theground-engaging member and concave outrigging flange defining the hollowinterior recess.